GR Research build at "God's Own Country"

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rajesh

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GR Research build at "God's Own Country"
« on: 15 Dec 2015, 03:38 pm »
Some of the regular folks would remember that a group of guys from an India centric forum had got together and got loudspeaker kits imported from GR Research. The entire saga of the import process was documented in this epic thread of that forum: http://www.hifivision.com/diy/19688-best-ever-deal-loudspeaker-kits.html

While participating members were free to choose any of the kits, a majority of us had chosen the X-Series kits, specifically the X-LS Classic / X-LS Encore kits, because of the stupendous VFM factor.

I went in for a 5.1 set up. So, in addition to the X-SLS Encore (Floor stander version using the X-LS kit) for the mains, I've gone in for X-CS Encore for the centre (not listed on the site), the A/V 1RS for the rear surrounds and the 12" Servo Controlled subwoofer driver to be driven by Rhythmik Direct Servo Sub woofer Amp in a sand filled sub woofer enclosure.

Several members have documented their builds but I was in blissful procrastination mode and am probably the last to take up the build because I was already having a good stereo rig and there was no place to keep the 5.1 setup in the smallish apartment that I was living then at Chennai.

When I got relocated to Trivandrum on transfer last year , I took a reasonably big house on purpose because I wanted to build the HT setup after all. I could locate a professional team of two brothers who make speaker boxes for theatres who also happened to be one of the interior work contractors of the organisation that I am working for.

We've started the work in all earnest sometime in January this year. However because of their professional commitments and my office hours, we could work only on one or two weekends every month.

I was clicking the pictures religiously during the build process but initial lethargy on my part and the tediousness of uploading the pictures later as the pictures got piled up have forced me to postpone documenting the build process as and when it happened.

Now that the build has come to close and I have a few queries to seek answers to, I've decided to start the thread and think of posting the pictures in due course.

These are the guys, The Band of Brothers in their old workshop where the build is progressing. They complement each other perfectly. The one on the left is the elder one Mr. Gopa Kumar who handles the logistics and administration and the one on right is Santhosh, who does the actual work.




To be continued...
« Last Edit: 15 Dec 2015, 05:47 pm by rajesh »

mresseguie

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Re: GR Research build at "God's Own Country"
« Reply #1 on: 15 Dec 2015, 03:48 pm »
Rajesh,

Hello. I think we have not chatted before, but I do recall your posting in the past and speaking about the kits you ordered. I'm glad to hear you are getting it accomplished. I like your comment about 'blissful procrastination'. It's a wonderful past time that my wife doesn't appreciate nearly as much as I do.  :(

I'm afraid your link to the epic build thread does not open for me.

Kindest regards,

Michael (normally in Oregon, but in Taiwan until March of 2016)

nickd

Re: GR Research build at "God's Own Country"
« Reply #2 on: 15 Dec 2015, 03:51 pm »
Rajesh,
Looking forward to reading as your thread comes together. The different materials, tools and techniques used will be fascinating to most of us. :thumb:

I'm also curios to see how your finish comes out. I suspect the humidity and heat there would give even the best painters trouble. :banghead:

Hank

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Re: GR Research build at "God's Own Country"
« Reply #3 on: 15 Dec 2015, 04:51 pm »
No matter where in the world, DIY smiles are present.  :thumb:

Guy 13

Re: GR Research build at "God's Own Country"
« Reply #4 on: 15 Dec 2015, 05:55 pm »
Hi Rajesh,
very anxious to see more (Pictures) of your project.

Guy 13

rajesh

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Re: GR Research build at "God's Own Country"
« Reply #5 on: 15 Dec 2015, 06:26 pm »
Thanks for the comments Micheal, Nick & Hank. :thumb:

I'm afraid your link to the epic build thread does not open for me.
I had modified the post. You should be able to open it now.

Looking forward to reading as your thread comes together. The different materials, tools and techniques used will be fascinating to most of us.
Yes, I'll post the pictures detailing the build in due course.

I'm also curios to see how your finish comes out. I suspect the humidity and heat there would give even the best painters trouble.
Yes also add dust to that list. They are used to it and surely know how to handle it.

No matter where in the world, DIY smiles are present.
Yeah, the feelings are he same. BTW, the thread title needs some explanation. I'm currently located in the Indian State named Kerala which is situated half the way across the globe to you. It is called "God's own Country" in Indian tourism circles because of it's unspoiled and beautiful tropical nature.

rajesh

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Re: GR Research build at "God's Own Country"
« Reply #6 on: 22 Dec 2015, 05:19 pm »
very anxious to see more (Pictures) of your project.

Hi Guy13,

I think our posts crossed. I was down with fever and flu for whole of last week. I'm up and running now. Here are the pics.

These guys make boxes for threatres throughout Kerala and Southern Tamil Nadu. In fact they have made speakers for theatres as far as Southern Andhra Pradesh. Santhosh has so much experience and knowledge that he can be an acoustic consultant. :)

Major part of tools used


The first cut:


Cutting in progress:


Making of Front Towers in progress:






Marking for drilling screw holes:


Drilling screw holes:


Screw Hole up close:


Braces in making:



Braces ready for fixing




Affixing the braces:






Cutting Driver holes (Tweeter)




Cutting Driver holes (Woofer)


Baffle fixed


Baffle upclose


Chamfering of woofer hole


Checking driver holes fit



Hole for sandfilling of bottom compartment


Making the sandfilling hole




Nylon plug fabricated for fixing on the sandfilling hole




Affixing the bitumen sheet on the cabinet walls


To be continued...



Guy 13

Re: GR Research build at "God's Own Country"
« Reply #7 on: 22 Dec 2015, 06:18 pm »
Hi Rajesh,
thanks for all the pictures.
Your post is very well documented with all those picures.
Their shop look like a mess, but that's not important,
it's the result that count.
Anxious to see the final result.
By the way, I did not see a bench saw ?
Only a circular saw ???

Thanks again.

Guy 13

rajesh

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Re: GR Research build at "God's Own Country"
« Reply #8 on: 22 Dec 2015, 07:27 pm »
@Guy13, thanks for your interest. You Westerners are much more meticulous lot, comparatively speaking. Here in India, there is a method in all the apparent madness. The workshop is case in the point.  :lol:

That's actually their old workshop where the build commenced about 10  months ago. They have since moved to a much tidier premises. I'll post the pics of the new premises in due course.

More to come...

mresseguie

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Re: GR Research build at "God's Own Country"
« Reply #9 on: 23 Dec 2015, 01:24 am »
Rajesh,

Thank you for posting these pictures. I almost feel I am there and I imagined smelling the dust.  :wink: I see you/they have chosen to use HDF rather than MDF. Those cabinets must be very solid and very heavy.  :thumb:

I have made just one pair of cabinets from scratch and suffered difficulty getting the pieces to properly align. It did not occur to me to use nails as line guides.  :duh: So simple yet so effective. If ever I build another pair of speakers, I will remember this.

Kindest regards,

Michael

JerryM

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Re: GR Research build at "God's Own Country"
« Reply #10 on: 23 Dec 2015, 01:29 am »
Awesome!!  :thumb:

Thanks for taking the time to share all of this. I look forward to the rest!

Have fun,

Jerry

Folsom

Re: GR Research build at "God's Own Country"
« Reply #11 on: 23 Dec 2015, 03:31 am »
To me it looks surprising you can see, like it's dark.

I love how a big group decided to build speakers, fun idea!

G Georgopoulos

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Re: GR Research build at "God's Own Country"
« Reply #12 on: 23 Dec 2015, 04:20 am »
wow lot's of pics
can't wait to see the spks complete... :green:

persisting1

Re: GR Research build at "God's Own Country"
« Reply #13 on: 23 Dec 2015, 07:32 pm »
Sand filled X-SLS Encores? Those are going to sound nice  :thumb:

Danny Richie

Re: GR Research build at "God's Own Country"
« Reply #14 on: 23 Dec 2015, 09:19 pm »
Looks good.

Rajesh, you need to buy those guys some new shoes.

bdp24

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Re: GR Research build at "God's Own Country"
« Reply #15 on: 24 Dec 2015, 07:32 am »
What the heck is bitumen? I mean, other than rubberized tar paper. I've seen the name for years, especially in the British press. I haven't found a source for it in the U.S., however.

rajesh

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Re: GR Research build at "God's Own Country"
« Reply #16 on: 2 Jan 2016, 06:51 am »
I see you/they have chosen to use HDF rather than MDF. Those cabinets must be very solid and very heavy.

My brief to them was simple; No compromises. Apparently those panels are the best that are available in the local market.

I have made just one pair of cabinets from scratch and suffered difficulty getting the pieces to properly align. It did not occur to me to use nails as line guides.  :duh: So simple yet so effective. If ever I build another pair of speakers, I will remember this.

I'm glad that you found the posts useful.

Awesome!!  :thumb:

Thanks for taking the time to share all of this. I look forward to the rest!

Have fun,

Jerry

Thanks for the kind words.

I love how a big group decided to build speakers, fun idea!

Yes, it took a huge effort from my side but the trust reposed on rank stranger by so many folks was amazing and motivated me to keep it going.


wow lot's of pics
can't wait to see the spks complete... :green:

Sure; more pics are in the offing.

Sand filled X-SLS Encores? Those are going to sound nice  :thumb:

Yes, making them as per the plan on the GR site.

Rajesh, you need to buy those guys some new shoes.

LOL. Most of the Indians are not used to wearing shoes. It is either "slippers" or "sandals". The tropical climes won't let them either. The exceptions are Corporate Executives, members of Armed Forces and some sections of urban crowd.

What the heck is bitumen? I mean, other than rubberized tar paper. I've seen the name for years, especially in the British press. I haven't found a source for it in the U.S., however.

Bitumen and Tar are the same, petroleum byproducts. But these sheets are not rubberised; just pure Tar sheets.

jzexport

Re: GR Research build at "God's Own Country"
« Reply #17 on: 3 Jan 2016, 12:10 am »
I love this thread. Way to go Rajesh and your compatriots! I have been all over the world and am always amazed at peoples' ingenuity, creativity and ability to accomplish amazing things with whatever tools and materials they have on hand. I hope you love your finished speakers.

Josh

Danny Richie

Re: GR Research build at "God's Own Country"
« Reply #18 on: 3 Jan 2016, 12:36 am »
I love this thread. Way to go Rajesh and your compatriots! I have been all over the world and am always amazed at peoples' ingenuity, creativity and ability to accomplish amazing things with whatever tools and materials they have on hand. I hope you love your finished speakers.

Josh

I agree.

rajesh

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Re: GR Research build at "God's Own Country"
« Reply #19 on: 4 Jan 2016, 06:14 am »
I love this thread. Way to go Rajesh and your compatriots! I have been all over the world and am always amazed at peoples' ingenuity, creativity and ability to accomplish amazing things with whatever tools and materials they have on hand. I hope you love your finished speakers.

Thank you for the encouragements Josh.  :thumb:

Because of the complexity of the design and build, making of the surround speakers has been the most rewarding experience from the viewpoint of learning carpentry techniques.

Tools used

Angled Circular Saw


Angle measuring tool




Hole Saw